Heterofilaments for cord reinforcement in rubber goods

ABSTRACT

In an improved power transmission belt, the circumferentially disposed reinforcing cords are made from multi-filament yarns of heterofilaments. These cords, when fused, have good inter-filament bonding without the solvent of the solvent/adhesive systems.

This is a division of application Ser. No. 08/323,164 filed Oct. 13,1994 pending which is a continuation-in-part of Ser. No. 08/020,875filed Feb. 19, 1993, abandoned.

FIELD OF THE INVENTION

This invention is directed to heterofilament yarns being used for thecord reinforcement in rubber goods, for example power transmissionbelts.

BACKGROUND OF THE INVENTION

Power transmission belts, for example V-belts and ribbed V-belts, arewell known (See: Wake, N.C., et al., "Textile Reinforcement ofElastomers", Applied Science Publishers, Englewood, N.J., 1982). Suchpower transmission belts typically comprise rubber impregnated fabriclayers disposed on the belt's innermost and outermost circumferentialsurfaces, and a layer of a masticated rubber/staple fiber mixture and alayer of circumferentially disposed reinforcing cord being sandwichedtherebetween. The reinforcing cord or "stiff cord" is typically madefrom an adhesive impregnated, multi-filament yarn. Exemplary yarnsinclude filaments of nylon, polyester, and rayon, polyester beingreferred because of its superior properties.

Generally, these belts are made by laying up the above-mentioned layers,in an inverted order, on a drum. First, a layer of rubber impregnatedfabric is laid on the drum. Then, the reinforcing cords are laid up.Next, a layer of masticated rubber/staple fiber is laid up. Finally, asecond layer of rubber impregnated fabric is applied to theconstruction. The foregoing is then vulcanized, thereby forming a "largetube". From this tube, individual belts are cut.

One problem with this type of belt is "cord pop-out". "Cord pop-out", orfraying of cord from the belt's cut edge, seriously diminishes thebelt's useable life span because the loss of cord from the beltaccelerates wear on the belt leading to its ultimate failure. Cordpop-out and situations which lead to cord pop-out can arise duringmanufacture and use of the belt. In manufacture, when belts are cut fromthe tube, the cord or the yarn in the cord can be stripped away. In use,as the belts leaves the sheave, the cord or the yarn may "pop-out" ofthe belt because of the reduction of lateral compressive force on thebelt.

"Cord pop-out" is such a serious concern that the reinforcing cords or"stiff cords" are impregnated with an adhesive to facilitateinter-filament bonding. Inter-filament bonding within the yarn and cordreduces the possibility of individual filaments popping from the beltand begin fraying from the belt. Typical adhesives for inter-filamentbonding include isocyanate systems which are normally applied to thecord in a solvent carrier. The solvent/isocyanate systems is necessaryso that the isocyanate penetrates in between the filaments of the yarnand thereby facilitates inter-filament bonding (See: Wake, W.C., Ibid.,pg. 89-90). These solvents, however, pose significant environmentalproblems (See: Wake, N.C., Ibid.). These adhesive systems forinter-filament bonding should be differentiated from theresinol-formaldehyde-latex (RFL) systems (aqueous based systems) whichare applied to the cord. The RFL systems enhance and promote adhesion ofthe cord to the surrounding rubber.

There is also a need to develop new cord reinforcement products for therubber goods industry. The rubber goods industry includes any rubberproduct which uses a reinforcing cord, e.g. power transmission belts,conveyor belts, tires, and the like. Polyester (i.e. polyethyleneterephthalate) reinforcement cord is a reinforcement product of choicein most of those applications because of its strength and dimensionalstability, but polyester cord suffers because of its inherently pooradhesion to rubber. Consequently, adhesives systems have been devisedthat overcome the poor adhesion. Work, however, continues to improve theadhesion of polyester to rubber.

Accordingly, there is a need to find a way to prevent cord pop-out inpower transmission belts without the use of the solvent carrier for theisocyanate adhesive system.

SUMMARY OF THE INVENTION

This invention is directed to an improved power transmission belt havingcircumferentially disposed reinforcing cords. Each cord is made frommulti-filament yarns. The improvement is the multi-filament yarnscomprise heterofilaments.

DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, there is shown in thedrawings a form which is presently preferred; it being understood,however, that this invention is not limited to the precise arrangementsand instrumentalities shown.

FIG. 1 is an isometric view of the cross section of a power transmissionbelt.

FIG. 2 is an isometric cross sectional view of a prior art cordcomprising of plurality of fibers.

FIG. 3 is an isometric view of a cord made with heterofilamentsaccording to the present invention.

FIG. 4-10 are charts that graphically illustrate the adhesion propertiesof the claimed invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, there is shown a power transmission belt 10. Belt10 is representative of the construction of power transmission belts,and illustrates the invention, however, this particular constructionshould not be construed as limiting the invention. Belt 10 is referredto, by those of ordinary skill in the art, as "cut edge" or "raw edge"V-belt. Those of ordinary skill will readily recognize the applicabilityof this invention to other power transmission belts, e.g. ribbedV-belts.

The components of belt 10 generally include: a rubber coated fabric 12;a layer 14 of masticated rubber with a fiber filler; a reinforced cordsection 16; and a rubber coated fabric 18. These power transmissionbelts may be manufactured in any conventional manner usingconventionally available components. See, for manner, for example see:"Vanderbilt Rubber Handbook", R. T. Vanderbilt Co., Inc., Norwalk, Conn.(1978).; Blow, C. M., et al. (ed.), "Rubber Technology and Manufacture",2nd Edition, The Plastics and Rubber Institute University Press, NY,N.Y., (1989).; and Wake, W. C., et al., "Textile Reinforcement ofElastomers", Applied Science Publishers, Englewood, N.J., (1982).; eachof these references are incorporated herein by reference.

The term "filament" or "fiber", as used herein, refers to the componentswhich make up a yarn. The term "yarn", as used herein, is a generic termfor a continuous strand of fibers, or filaments. The term "cord", asused herein, refers to the product formed by twisting together or"plying" one or more yarns.

Referring to FIGS. 2 and 3, a prior art cord 20 and inventive cord 30are illustrated respectively. Both cords are shown as being made fromthree plied yarns. Cords used in the manufacture of power transmissionbelts are not so limited and neither is the instant invention. Prior artcord 20 comprises three plied yarns 22. Yarn 22 may be a 1000 totaldenier yarn of 192 filaments. The individual filaments are boundtogether with an adhesive system (i.e., the inter-filament bondingsystems) as discussed above.

Cord 30 comprises yarns 32. Yarns 32 comprise heterofilaments 34.Heterofilaments 34 are illustrated as, but not limited to, sheath/coreheterofilaments. Sheath 36 surrounds core 38. These heterofilaments 34include a fuseable portion (e.g., sheath 36) which can eliminate theneed for the solvent/ adhesive systems, because the heterofilaments,when heated under pressure, as is well known, can bond to one another.These heterofilaments 34 may be fused prior to manufacture of the beltor during vulcanization of the belt or a combination of both.

Heterofilaments are known in the art (e.g., see U.S. Pat. Nos. 3,616,183and 3,998,988, both are incorporated herein by reference).Heterofilaments are known as "bi-component fibers", "conjugate fibers","heterofils", or "composite fibers". Heterofilament, as used herein,refers to a filament made from a thermoplastic, synthetic, organicpolymer composed of a relatively high melting polymer component and arelatively low melting polymer component. Generally, the heterofilamentsare either a sheath/core type or a side-by-side type. In eitherembodiment, both components of the heterofilament will, of course, bepresent in a continuous phase.

The high melting point polymer component may have a melting point about30° C. greater than that of the lower melting point polymer component.Preferably, a sheath/core heterofilament is used, with the corecomprising of about 80% of the heterofilament.

The polymer used for the production of the heterofilament is athermoplastic, synthetic, organic polymer. Examples of the polymerinclude, but are not limited to: polyesters; polyamides; polyolefins;polystrenes; polyurethanes; polyesteramides; and mixtures thereof.

The high-melting point polymer component maybe a polyester or apolyamide. The polyester maybe polyester terephthalate (PET). Thepolyamide maybe nylon-6 or nylon-6,6.

The low-melting point polymer component maybe selected from thefollowing exemplary polymers: polystrenes; polyolefins; polyvinyls;polyesters; or polyurethanes. Non-limiting examples of the foregoingpolymers are as follows: polyolefins; polyethlene, polyproplene;polyvinyls-polyacrylonitrile, polyvinyl chloride; and polyesters -polybutylene terephthalate or polyester modified with an acid or aglycol. Examples of the forementioned acid include, but are not limitedto: isophthalic acid; phthalic acid; adipic acid; sebacic acid. Examplesof the forementioned glycol include, but are not limited to:trimethylene glycol; hexamethylene glycol; cyclohexane dimethanol.

Preferably, the core comprises polyethylene terephthalate (PET) and thesheath comprises polybutylene terephthalate (PBT).

The PBT/PET sheath/core heterofilament has improved adhesion to rubberthat is beneficial in the manufacture of V-belts and other rubberproducts requiring fiber reinforcement.

The cord to rubber adhesion is improved by the use of PBT/PET-based cordversus conventional polyethylene terephalate cords (i.e.,non-heterofilaments). This effect is applicable to any adhesiveactivated or non-adhesive activated yarn using an adhesive system of,for example, Resinol-Formaldehyde-Latex (RFL) adhesives and RFL'smodified with phenol-blocked methylene diisocyanates and/orcaprolactan-blocked methylene diisocyanate, and any of the foregoingmaybe modified with a topcoat (for example containing 0.10% by weightsilane epoxy). The effect is not apparently applicable when acombination of Ner 10A epoxy and phenol-blocked methylene diisocyanateadhesives is used.

EXAMPLE

Improved cord to rubber adhesion is demonstrated in the followingexamples. The adhesion of rubber to cord is examined by comparing aconventional polyester (i.e. polyethylene terephthalate) cord (i.e.Hoechst Celanese's T793 yarn product) to the inventive material (cordmade from PBT/PET sheath/core yarns). The cord construction is 1000/2/3,unless otherwise noted. Each yarn (conventional and heterofilament) isadhesive activated, for example see U.S. Pat. No. 5,328,765 incorporatedherein by reference. The cords are treated with conventional RFL's orRFL's modified with phenol-blocked methylene diisocyanate with a twozone drying/cure of either 300° F. for 90 sec at 4530 g tension followedby 460° F. for 90 sec at 6804 g tension, or 300° F. for 90 sec at 4530 gtension followed by 450° F. for 90 sec at 6804 g tension, or 300° F. for90 sec at 4530 g tension followed by 450° F. for 90 sec at 6804 gtension. The cords treated with the combination of Ner 10A epoxy andphenol-blocked methylene diisocyanate were treated in a double dipsystem with the epoxy cure at 440° F. for 30 sec at 4530 g tension andthe RFL cure at 225° F. for 70 sec at 4530 g followed by 450° F. for 50sec at 6804 g tension.

The test strips were made as follows: A layer of rubber is wrappedaround a wind up drum. This is followed by a layer of the test sample.The samples are cut and sandwiched with a layer of thin rubber betweenthem. After curing in a steam heated press, the samples are cut into oneinch strips and pulled apart under heat on an Instron-type tensiletester. The average number of pounds to pull the strip apart is ameasure of the peel resistance of the sample. Samples maybe tested atroom temperature, at 250° F. (in an environmental chamber), or after a 2hr steaming in an autoclave (15 psi steam).

The rubbers used include: "PET" from Michelin (a tire rubber formerly aproduct of Uniroyal-Goodrich); Neoprene "D" (used in V-belts); andneoprene (a Goodyear product for V-belts).

The results are reported as follows: Adhesion (in pounds/inch) is showna function of the cord and adhesive system; also reported is a visualrating of 0-5 that indicates where failure occurred i.e. at thecord/rubber interface or in the rubber, wherein "0" indicates no rubbertear and "5" indicates complete rubber tear.

In FIGS. 4, 5, & 7, for each sample, the left hand bar is testing atroom temperature, the middle bar, testing after 2 hr steaming, and theright, testing at 250° F. In FIGS. 6, & 8-10, for each sample, the leftbar is testing at room temperature, and the right, after 2 hr. steaming.

In FIG. 4, "PET" type rubber is used and "A" is polyethyleneterephthalate (PET) cord with RFL, "B" is PET cord with RFL and 5% byweight phenol-blocked methylene diisocyanate (LVBI), "C" is PBT/PET cordwith RFL, and "D" is PBT/PET cord with RFL and 5% by weightphenol-blocked methylene diisocyanate (LVBI).

In FIG. 5, Neoprene "D" rubber is used and "A" is PET cord with RFL, "B"is PET cord with RFL/5% LVBI, "C" is PBT/PET cord-RFL, and "D" isPBT/PET cord-RFL/5% LVBI.

In FIG. 6, "PET" rubber is used and "A" is PET cord with Ner 10Aepoxy/LVBI & RFL, "B" is PBT/PET cord-Ner 10A/LVBI & RFL, "C" is PBT/PETcord-Net 10A/LVBI & RFL with a topcoat (containing 0.1% by weight silaneepoxy), "D" is PET cord RFL/5% LVBI, "E" is PBT/PET cord with RFL/5%LVBI, and "F" is PBT/PET cord with RFL/5% LVBI with a topcoat(containing 0.1% silane) epoxy.

In FIG. 7, neoprene rubber is used and "A" is PET cord-RFL, "B" is PETcord-RFL/5% LVBI, "C" is PBT/PET cord-RFL and "D" is PBT/PET cord-RFL/5%LVBI.

In FIG. 8, neoprene rubber is used and "A" is PET cord-RFL, "B" isPBT/PET cord-RFL, "C" is PBT/PET cord-RFL and a topcoating (0.1% silaneepoxy), "D" is PET cord-RFL/5% LVBI, "E" is PBT/PET cord-RFL/5% LVBI,"F" is PBT/PET cord-RFL/5% LVBI and a topcoating (0.1% silane epoxy).

In FIG. 9, "PET" rubber is used and "A" is PET cord-RFL, "B" is PBT/PETcord-RFL, "C" is PBT/PET cord-RFL, and a topcoating (0.1% silane epoxy),"D" is PET cord-RFL/LVBI, "E" is PBT/PET cord-RFL/LVBI, and "F" isPBT/PET cord-RFL/LVBI, and a topcoating (0.1% silane epoxy).

In FIG. 10, neoprene rubber is used and "A" is PET-Ner 10A epoxyLVBI&RFL, "B" is PBT/PET-Ner 10A epoxy/LVBI&RFL; "C" is PBT/PET-Ner 10Aepoxy/LVBI&RFL and a topcoat (0.1% silane epoxy); "D" is PET-RFL 15%LVBI; "E"-PBT/PET-RFL 15% LVBI; and "F"-PBT/PET-RFL 15% LVBI and topcoat(0.1% silane epoxy).

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes thereof and,accordingly, reference should be made to the appended claims, ratherthan to the foregoing specification, as indicating the scope of theinvention.

I claim:
 1. A method of manufacturing a multifilament heterofilamentyarn comprising: providing a plurality of individual heterofilamentseach comprising a core component composed of synthetic polymericmaterial having a given melting point temperature and a sheath componentsurrounding said core component essentially of poly(butyleneterephthalate) polymer having a melting point temperature of saidsynthetic polymeric material; bundling together said plurality ofindividual heterofilaments to form a multifilament composite; andmelting the sheath components of the heterofilaments at a temperaturebetween the melting point temperatures of said core and sheathcomponents into a multifilament composite yarn.
 2. The method of claim1, wherein said core component is selected from a group consisting ofpolyester and polyamide.
 3. The method of claim 1, wherein saidsynthetic polymeric materials is polyethylene terephthalate.